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Harness And Wire Electrical Schematic Symbols

RENR2311-03
August 2006

Symbols

Pressure
Symbol

Temperature
Symbol

Level
Symbol

Flow
Symbol

Circuit Breaker
Symbol

Symbols and Definitions


Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.
UNIT INJECTOR (P91)

INLET AIR TEMPERATURE SENSOR (P89)

TURBO OUTLET PRESSURE


SENSOR (J23)

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.

ATMOSPHERIC PRESSURE SENSOR (J27)

Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
No circle indicates that the wire cannot be disconnected from the component.

TDC PROBE CONN (J26)


BACKUP SPEED/TIMING
SENSOR (P44)

GROUND

Ground (Wired): This indicates that the component is connected to a grounded wire. The
grounded wire is fastened to the machine.
Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

ECM CONN (P2)

Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.

3406E and 3456 Generator Set Engine


Electrical System

PRIMARY SPEED/TIMING
SENSOR (P20)

3406E:
1MZ1-UP

Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
the gauge of the temperature or pressure.

Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.


It has a coil that makes an electromagnet when current flows through it. The
electromagnet can open or close the switch part of the relay.

3456:
3PG1-UP

Solenoid: A solenoid is an electrical component that is activated by electricity. It has a


coil that makes an electromagnet when current flows through it. The electromagnet
can open or close a valve or move a piece of metal that can do work.
Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is
activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
that make electromagnet when current flows through them. It also has an internal switch that places
the latch coil circuit open at the time the coil latches.

FUEL TEMP SENSOR (P43)

Harness and Wire Symbols

ECM CONN (P1)

Wire,
Cable,
or
Harness
Assembly Identification: Includes
Harness Identification Letters and
Harness Connector Serialization
Codes (see sample).

TDC PROBE CONN (P26)

E93188

Harness Identification Letter(s):


(A, B, C, ..., AA, AB, AC, ...)

L-C12
3E-5179

AG-C4
111-7898

L-C12
3E-5179

Part Number: for Connector Plug

Harness Connector Serialization Code:


The "C" stands for "Connector" and the
number indicates which connector in the
harness (C1, C2, C3, ...).

Part Number: for Connector Receptacle

2
Plug

Receptacle
Pin or Socket Number

1
2

Deutsch connector: Typical representation


of a Deutsch connector. The plug contains all
sockets and the receptacle contains all pins.

1
2

Sure-Seal connector: Typical representation


of a Sure-Seal connector. The plug and receptacle
contain both pins and sockets.

5A
Fuse (5 Amps)

9X-1123

Component
Part Number

325-AG135 PK-14
Harness identification code:
This example indicates wire group 325,
wire 135 in harness "AG".

Printed in U.S.A.

J1 / P1

Electronic Control Module (ECM) Connector (40-Pin, Key A)

J2 / P2

Electronic Control Module (ECM) Connector (40-Pin, Key B)

J3 / P3

Customer Connector (40-Pin0

J20 / P20

Bottom Speed / Timing Sensor Connector (2-Pin)

J21 / P21

Engine Coolant Temperature Sensor Connector (3-Pin)

J22 / P22

Engine Oil Pressure Sensor Connector (3-Pin)

J23 / P23

Turbocharger Outlet Pressure Sensor Connector (3-Pin)

J26 / P26

Timing Calibration Connector (2-Pin)

J27 / P27

Atmospheric Pressure Sensor Connector (3-Pin)

J31 / P31

Exhaust Temperature Sensor Connector (3-Pin)

J34 / P34

Engine Coolant Level Sensor Connector (3-Pin)

J43 / P43

Fuel Temperature Sensor Connector (3-Pin)

J44 / P44

Top Speed / Timing Sensor Connector (2-Pin)

J49 / P49

Fuel Pressure Sensor Connector (3-Pin)

J51 / P51

Engine Oil Temperature Sensor Connector (3-Pin)

J60 / P60

Engine Service Tool Connector (9-Pin)

J89 / P89

Inlet Air Temperature Sensor Connector (3-Pin)

J91 / P91

Electronic Unit Injector Connector (12-Pin)

J99 / P99

Caterpillar Monitoring System Main Module Connector

Sensor and Electrical Components


Location

Description

Secondary Speed / Timing Sensor

Primary Speed / Timing Sensor

Turbocharger Outlet Pressure Sensor

Fuel Temperature Sensor

Inlet Air Temperature Sensor

Timing Calibration Connector

Atmospheric Pressure Sensor

Engine Oil Pressure Sensor

Engine Coolant Temperature Sensor

9
(Dimensions: 25 inches x 24 inches)

Functional Description

12 Page,

Jack / Plug

RENR2311-03

2006 Caterpillar
All Rights Reserved

Electrical Connectors and Functions

Wire Gauge
Wire Color

CIRCUITS WITHIN THIS AREA ARE OPTIONAL ATTACHMENTS


MAIN UNIT

OPTIONAL EMS DISPLAY MODULES

(NOTE G)

TACHOMETER

QUAD GAUGE

(NOTE G)

10

15

(NOTE G)

20

OPTIONAL REMOTE
TACHOMETER OR
QUAD GAUGE
(NOTES G & M)

25

8
7
6
5
4
3
2
1

6
5
4
3
2
1

6
5
4
3
2
1

40
39
38
37
36
32
31
30
29
28
27
26
24
22
21
19
18
17
16
12
11
10
9
8
6
3
33
4
7
13
23
20
35
34
25
15
14
5
2
1

0 RPM X100 30

(NOTE F)

(148-5625)

4
3
2
1

DATA LINK
BOOSTER
(143-4518)

1
2
3
4
5
6
7
8
9
10
11
12

+24V
- BAT.
US/METRIC
SCROLL FORWARD
CAT DATA LINK CAT DATA LINK +
UNUSED
WARNING LAMP
WARNING
BACKLIGHT LAMP PWR
SCROLL BACKWARD

DIAGRAM
148-5625

(NOTE H)

-V OUT

(NOTE M)

+V OUT

DC/DC CONVERTER
(127-8853)
(NOTES L & M)
-V IN

L983/WH
L984/OR
L985/YL
A706/GY
A705/BU
A704/GN
A703/BR
A702/PU
A701/GY

ECM

BKUP SP/TMG SNSR


OVERSPEED VERIFY SW
THROTTLE POSITION SNSR
DIGITAL SNSR RETURN
ANALOG SNSR PWR (5V)
ANALOG SNSR RETURN
UNUSED
UNUSED
PTO ENABLE SW
WARNING LAMP
PTO RAMP UP SW
PTO RAMP DOWN SW
COOLANT LEVEL SNSR
REMOTE SHUTDOWN SW
DIAGNOSTIC LAMP
DIGITAL SNSR POWER (+8V)
INTERMEDIATE SPEED SW
ETHER START VALVE RELAY
STARTING AID SW
MAINTENANCE OVERDUE LAMP
UNUSED
UNUSED

+BAT. (UNSWITCHED)(NOTE B)
+BAT. (SWITCHED)
J1939 SHIELD
J1939 DATA J1939 DATA +
ATA DATA LINK ATA DATA LINK +
CAT DATA LINK CAT DATA LINK +
-BAT.

J1/P1
18
32
37
29
36
30
31
38
20
27
25
15
2
8
22
35
24
34
13
21
28
40
10
11
12
14
16
17
19
23
4
6
26
39
33
1
7
3
9
5

C OFF
ON
S ST

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS


(NOTE M)

AIR SHUTOFF
SOLENOID

R
CYL
NO.6

CYL
NO.5

CYL
NO.4

CYL
NO.3

CYL
NO.2

CYL
NO.1

CB
15A

CIS

15A

L983/WH
L984/OR
L985/YL
A706/GY
A705/BU
A704/GN
A703/BR
A702/PU
A701/GY
G810/PU
G811/YL
G809/GN
G808/BU
997/OR
993/BR
C967/BU
996/GN
998/BR
999/WH
995/BU
A746/PK
A747/GY
994/GY
F421/YL
413/BR
G969/YL
G971/BR
G970/BU
G469/BU
M904/OR
G468/GN
F426/BU
E798/PK
E797/WH

A
C
B

+8V
SIGNAL
RETURN

(P19A)
AUXILIARY
TEMP SNSR
(131-0427)

A
C
B

+8V
SIGNAL
RETURN

(P34)
COOLANT LEVEL SNSR
(111-3794)
OFF ENGINE

A
C
B

+5V
SIGNAL
RETURN

(P19B)
AUXILIARY
PRESS. SNSR
(161-9932)

+
G810/PU
G811/YL

P26/J26
1
G808/BU
2
G809/GN

M909/GN

F732/PK
387/PK
A307/GY
A274/BK
125/OR
A243/BK
M908/YL
M905/PU
381/PU
F420/GN
G955/GN
G967/WH
E452/WH
F716/WH
F404/RD
167/OR
G968/WH
382/PK
M910/OR
F424/YL
M902/OR
M903/GN

MTR BAT

CB
(NOTE D)

997/OR
C967/BU
993/BR

P88/J88
A
C
B

+5V
SIGNAL
RETURN

INLET AIR TEMP SNSR


(107-8618)

996/GN
998/BR
999/WH

J20/P20
A
B
C

+12V
RETURN
SIGNAL

PRIM. SP/TMG SNSR


(127-1008)

998/BR
996/GN
F732/PK

J44/P44
B
A
C

RETURN
+12V
SIGNAL

BKUP SP/TMG SNSR


(127-1008)

997/OR
995/BU
993/BR

P21/J21
A
C
B

+5V
SIGNAL
RETURN

COOL. TEMP SNSR


(102-2240)

997/OR
A746/PK
993/BR

J23/P23
A
C
B

+5V
SIGNAL
RETURN

TURBO OUTLET PRESS.


(161-9927)

997/OR
A747/GY
993/BR

J27/P27
A
C
B

+5V
SIGNAL
RETURN

ATMOSPHERIC PRESS.
(161-9925)
(163-8350 NOTE N)
(194-6722 NOTE P)

997/OR
994/GY
993/BR

J22/P22
A
C
B

+5V
SIGNAL
RETURN

CB
(NOTE B)

ALT
GND

SM

BATTERY
DISCONNECT
SWITCH
(NOTE B)
+

P43/J43
A
C
B

+5V
SIGNAL
RETURN

FUEL TEMP SNSR


(102-2240)

997/OR
413/BR
993/BR

J49/P49
A
C
B

+5V
SIGNAL
RETURN

FUEL PRESSURE SNSR


(161-9930)

150/OR
G971/BR
G969/YL
G468/GN
E452/WH
167/OR
A274/BK
G469/BU
A307/GY
125/OR
A243/BK
382/PK
M910/OR
F426/BU
M909/GN
F716/WH
G968/WH
387/PK
M904/OR
381/PU
G970/BU
G955/GN
G967/WH
F424/YL
F404/RD
F420/GN
M905/PU
120/YL
892/BR
893/GN
M903/GN
M902/OR
E794/YL
E793/BU
E797/WH
E798/PK
M908/YL
A234/BK
K900/YL
K990/GN

(NOTE J)

J3/P3
1
4
5
11
36
8
9
33
10
14
15
22
38
12
2
27
28
40
19
29
3
30
39
13
24
25
20
26
6
7
21
23
31
32
34
35
37
16
17
18

STARTING AID SW
MAINTENANCE CLEAR SW
TORQUE LIMIT SW
REMOTE SHUTDOWN SW
INTERMEDIATE SPEED SW
OVERSPEED VERIFY SW
PTO INTERUPT SW
PTO ENABLE SW

PTO RAMP
UP/DOWN SWITCH
MAINTENANCE
OVERDUE LAMP
DIAGNOSTIC LAMP
WARNING LAMP

MAX LENGTH 1 METER


(NOTE M)
C
A
B
MAX LENGTH 30 METERS
DEVICE

TERMINATION
RESISTOR
(134-2540)
(NOTE C & M)

120/YL
229/BK
893/GN
892/BR
E793/BU
E794/YL

J60
A
B
C
D
E
F
G
H
J

+BAT.
-BAT.
NC
CAT DATA
CAT DATA
NC
NC
ATA DATA
ATA DATA

(P35)
THROTTLE POSITION
SNSR (219-2384)

ETHER
VALVE

+BAT. (UNSWITCHED)
AIR SHUTOFF SOLENOID
SOLENOID COMMON
AUXILIARY TEMP SNSR
COOLANT LEVEL SNSR
DIG SNSR PWR (+8V)
DIG SNSR RETURN
AUXILIARY PRESS. SNSR
THROTTLE POSITION SNSR
ANLG SNSR PWR (+5V)
ANLG SNSR RETURN
ETHER START VALVE RELAY
STARTING AID SW
MAINTENANCE CLEAR SW
TORQUE LIMIT SW
REMOTE SHUTDOWN SW
INTERMEDIATE SPEED SW
OVERSPEED VERIFY SW
PTO INTERRUPT SW
PTO ENABLE SW
NC
PTO RAMP UP SW
PTO RAMP DOWN SW
MAINTENANCE OVERDUE LAMP
DIAGNOSTIC LAMP
WARNING LAMP
NC
+BAT. (SWITCHED)
CAT DATA LINK CAT DATA LINK +
NC
NC
ATA DATA LINK +
ATA DATA LINK NC
MAX LENGTH 0.2 METERS
NC
NC
C
J1939 SHIELD
A
J1939 DATA +
B
J1939 DATA (153-2707)
(NOTES E & M)

150/OR
120/YL
A234/BK
K990/GN
K900/YL
E793/BU
E794/YL
892/BR
893/GN
229/BK

SIG
+ BAT.
- BAT.

BATTERY

ENG OIL PR SNSR


(161-9930)

997/OR
F421/YL
993/BR

C
A
B

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

A
B
C

MAX LENGTH 40 METERS

120

(Dimensions: 25 inches x 24 inches)

12 Page,

RENR2311-03

TORQUE LIMIT SW

SMMS

120

INJECTOR COMMON 1 & 2


INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6
INJECTOR 6
INJECTOR 5
INJECTOR 4
INJECTOR 3
INJECTOR 2
INJECTOR 1
TDC PROBE +
TDC PROBE TDC SERVICE PROBE TDC SERVICE PROBE +
ANALOG SNSR POWER (+5V)
ANALOG SNSR COMMON
INLET AIR TEMP SNSR
+V ENG SP/TMG
ENG SP/TMG COMMON
PRIM. SP/TMG SNSR
COOL. TEMP SNSR
TURBO OUTLET PRESS.
ATMOSPHERIC PRESS. SNSR
ENG OIL PRESS. SNSR
FUEL TEMP SNSR
FUEL PRESS. SNSR
SOLENOID COMMON
AIR SHUTOFF SOL
UNUSED
AUXILIARY PRESSURE SNSR
PTO INTERRUPT SW
AUXILIARY TEMP SNSR
MAINTENANCE CLEAR
UNUSED
UNUSED

J2/P2
5
17
27
34
28
22
18
12
6
39
4
10
40
36
30
2
1
29
37
14
23
20
8
3
9
7
13
19
15
26
24
31
25
38
11
16
21
32
33
35

P91/J91
12
L983/WH
10
L984/OR
8
L985/YL
6
A706/GY
5
A705/BU
4
A704/GN
3
A703/BR
2
A702/PU
1
A701/GY
11
9
7

+V IN

A
B
C
E
D
F
G
J
H

+ BAT.
- BAT.
CAT DATA LINK CAT DATA LINK +
ATA DATA LINK +
ATA DATA LINK -

(J42)
CUST. SUPPLIED ENG
SERVICE TOOL CONN

TERMINATION
RESISTOR
(134-2540)
(NOTE C & M)

COMPONENTS ARE SHOWN WITH THE KEY OFF


LINK +
LINK -

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST


HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL.

LINK LINK +

ABBREVIATION

GROUND STUD
(NOTE A)

(+) BATTERY
(+) BATTERY SWITCHED
STARTING CIRCUIT
(-) BATTERY / SENSOR RETURN
SENSOR / ACTUATOR SUPPLY
SIGNAL PLUS TO ECM
SIGNAL MINUS TO ECM
CONTROL PLUS FROM ECM
CONTROL MINUS FROM ECM
CAT DATA LINK
J1939 DATA LINK

ALT
ATA
CB
CIS
DIG
ECM
NC
PWM
SM
SMMS

ALTERNATOR
AMERICAN TRUCKING ASSOCIATION
CIRCUIT BREAKER
CUSTOMER IGNITION SWITCH
DIGITAL
ELECTRONIC CONTROL MODULE
NO CONNECTION
PULSE WIDTH MODULATION
STARTING MOTOR
START MOTOR MAG SWITCH

NOTE B: TO AVOID LOSS OF JOB DATA STORED BY THE ECM,


DISCONNECT SWITCHES SHOULD NOT INTERRUPT EITHER THE ECM
BATTERY (-) OR UNSWITCHED BATTERY (+) LINES
NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR
TO TERMINATION RESISTOR) IS 40 METERS
NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION
NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939
SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS
NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR
MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION
NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING
STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE
OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO
A MAIN EMS MODULE
NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED.
IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO
BATTERY (-) IS REQUIRED
NOTE J: 4 AWG WIRE
NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-)
THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS
ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING
THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS
NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER
FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS
SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS
1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR
NOTE M: REFER TO THE INSTALLATION GUIDE FOR ADDITION
INSTALLATION DETAILS
NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES
WITHOUT CATERPILLAR ENGINEERING APPROVAL
UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE SXL OR
EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708
ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN
ENGINE FEATURES.
NOTE N: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS
OTHER THAN UNDERGROUND MINING
NOTE P: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY

THIS SCHEMATIC (130-5614 CHG09) IS FOR THE 3406E & 3456 ENGINE.